Method of Making an Absorbent Composite and Absorbent Articles Employing the Same

ABSTRACT

Disclosed is an absorbent core composite for a disposable absorbent article. The absorbent composite has a first fabric, a body side second fabric, and a plurality of aggregates of superabsorbent particles (SAP) situated between the first fabric second fabric. About each of a plurality of the SAP aggregates, an arrangement of spaced apart bond sites secures the second fabric to the first fabric and form a pocket in which the SAP aggregate is secured between the first fabric and the second fabric. The body side second fabric is a bulky nonwoven including fibers that entangle at least some particles in the SAP aggregate.

BACKGROUND

The present application is a Continuation application of U.S.application Ser. No. 15/669,714, filed on Aug. 4, 2017 (now allowed),which is a Continuation of U.S. application Ser. No. 14/214,868, filedon Mar. 15, 2014 (now U.S. Pat. No. 9,789,014), which is aContinuation-in-Part of U.S. application Ser. No. 14/026,927 filed onSep. 13, 2013 (now U.S. Pat. No. 9,566,198), which claims the benefit ofU.S. Provisional Application Ser. No. 61/801,620, filed on Mar. 15, 2013(now expired), which disclosures are hereby incorporated by referencefor all purposes and made a part of the present disclosure.

The present disclosure relates generally to an absorbent composite (orabsorbent core laminate) and a method of making an absorbent composite.The present invention also relates generally to disposable absorbentarticles employing absorbent composites and methods of making same. Suchdisposable absorbent articles include diapers, training pants, adultincontinence products, bodily exudates absorbing products, femininehygiene products, and other absorbent products (collectively “disposableabsorbent articles” or “disposable absorbent products”).

Disposable absorbent articles typically employ three basic structuralelements: a topsheet that forms the inner surface, a backsheet thatforms the outer surface, and an absorbent core that is interposedbetween the topsheet and the backsheet. The topsheet is designed toallow liquid to pass from outside the absorbent article through thetopsheet and into the absorbent core. The topsheet may be made out of arange of liquid and vapor permeable hydrophilic or hydrophobicmaterials. The permeability of the topsheet can be increased by usingsurface activation agents (“surfactants”). Surfactants lower the surfaceenergy or the contact angle of the liquid-solid interface and facilitatethe liquid's passage through the topsheet.

The backsheet is designed to prevent fluid from passing from theabsorbent core through the backsheet and out of the absorbent article.The backsheet may be made out of an impermeable film that extends thefull width of the article or a combination of cloth-like material andimpermeable film. The backsheet may also have vapor transmissionproperties (“breathability”) that allow vapor to pass through thebacksheet without releasing fluid stored in the absorbent core. Thebacksheet may also be made from a liquid impermeable but vaportransmittable non-woven material such as spunbond, melt-blow, spun-bond(“SMS”); spun-bond, melt-blown, melt-blown, spun-bond (“SMMS”); micro,nano, or splitable fibers; spun melt or spun laced; carded; and thelike.

The absorbent core is designed to contain and distribute fluid thatpasses through the topsheet. A typical absorbent core is made out of ahigh or super absorbent polymer (SAP) stabilized by an absorbent matrix.SAP is commonly made out of materials such as polyvinyl alcohol,polyacrylates, various grafted starches, and cross-linked sodiumpolyacrylate. SAP can be in the form of particles, fibers, foams, web,spheres, agglomerates of regular or irregular shapes, and film. Theabsorbent matrix is typically a de-fiberized wood pulp or similarmaterial. The absorbent matrix is very bulky relative to the topsheet,backsheet, and SAP. Most of a diaper's thickness comes from theabsorbent core.

Increasingly, consumers of absorbent articles are demanding thinnerabsorbent articles. To meet these demands, manufactures are decreasingthe thickness of absorbent articles by decreasing the amount ofabsorbent matrix used in absorbent cores. Although the resultingabsorbent cores are thinner, they suffer in performance. As the amountof absorbent matrix is reduced, it is less effective in stabilizing theSAP-preventing the SAP from migrating within the absorbent core. As SAPmigrates within the core, the absorbent core loses its effectiveness andno longer has uniform absorbency. For example, SAP that is not containedtends to bunch up in wetted areas and is inefficient for handlingsubsequent discharges.

Manufacturers have attempted to solve this problem by creating small,individual SAP pockets or by gluing the SAP. These solutions, however,have been largely unsuccessful. The SAP pockets merely limit themigration to movement within the pockets. However, because there isstill a movement of the particles, the absorbent core does not exhibituniform absorbency. Gluing the SAP stabilizes the SAP, but results in anuncomfortably stiff absorbent core and a loss in the SAP's swellingcapacity. Applicants have also discovered that may of the methods tocontain the SAP can negatively impact SAP and the absorbent core'scapacity to receive and distribute intake.

Accordingly, there exists a need for an improved absorbent product thatcontinues the trend of decreasing product thickness, while minimizingproduct stiffness and otherwise exhibiting excellent absorbency andfluid handling properties. The specification of U.S. Pat. No. 8,148,598,which is commonly assigned and designates at least one common inventoras the present application, describes a prior improvement to the stateof the art and serves as background to the present disclosure. The '598patent document is hereby incorporated by reference, in its entirety,for all purposes and made a part of the present disclosure. The presentdisclosure may, in one respect, be regarded as continuing and furtheringthe effort to provide improved absorbent products and methods ofmanufacturing.

BRIEF SUMMARY

In one aspect, the disclosure provides improved absorbent composites andmethods of making the composite. Embodiments are disclosed that focus onthe composition or arrangement of components of the absorbent composite.In one embodiment, an absorbent core composite for a disposableabsorbent article has a first fabric, a body side second fabric, and aplurality of aggregates of superabsorbent particles (SAP) situatedbetween the first fabric second fabric. About each of a plurality of theSAP aggregates, an arrangement of spaced apart bond sites secure thesecond fabric to the first fabric and form a pocket in which the SAPaggregate is secured between the first fabric and the second fabric. Thebody side second fabric is a bulky nonwoven including fibers thatentangle at least some particles in the SAP aggregate. In preferredembodiments, a pattern of adhesive may be preapplied on the first fabric(e.g., a pattern having a plurality of intersecting loops defining openregions free of adhesive).

In another aspect, a method is disclosed for manufacturing an absorbentcomposite laminate for a disposable absorbent article. The methodentails conveying a first fabric into position to receive superabsorbentparticles (SAP) and depositing SAP on the first fabric to providediscrete aggregates of SAP. A second fabric of a bulky nonwoven is thenconveyed and positioning relative the first fabric such that fibers ofthe bulky nonwoven entangle particles in a top layer of particles of theSAP aggregate. This secures, at least partly, the SAP aggregatetherebetween. The first and second fabric are then bonded at a networkof bond sites to form an elongated laminate having a plurality ofpockets of SAP aggregate, whereby each pocket is defined by bond sitespositioned about a SAP aggregate and securing the second fabric to thefirst fabric; and conveying the elongated laminate, whereby the bulkynonwoven and pockets inhibit SAP particle migration from said pockets.In preferred embodiments, the bond sites are bond points and/or the bondsites form diamond shaped pockets and a corresponding grid without anydirect straight line paths to the side margins.

A disposable absorbent article is also disclosed having a chassis bodydefined by a first end margin and a second end margin longitudinallyspaced from the first end margin, the end margins partially definingfront and back waist regions that are fastenable about a waist of auser. The article further includes a topsheet, a backsheet, and anabsorbent composite disposed between the topsheet and backsheet. Theabsorbent composite includes a first fabric, a second fabric bonded tosaid first fabric, absorbent particles secured between the first andsecond fabric. The first fabric is intermittently attached to the secondfabric to define a plurality of pockets situated between the firstfabric and the second fabric and containing an aggregate ofsuperabsorbent particles (SAP), wherein discontinuous and spaced apartbond sites secure the first fabric with the second fabric. The secondfabric is a bulky nonwoven material positioned on a bodyside of theabsorbent composite and over the SAP aggregate such that fibers of thebulky nonwoven entangle superabsorbent particles, wherein the SAPaggregate is free of an absorbent matrix in a middle portion extendingfrom beneath the bulky nonwoven material.

In another aspect, an absorbent composite is disclosed having a bulkynonwoven substrate, a top fabric bonded with the bulky nonwovensubstrate, and a layer of superabsorbent particles (SAP) securedtherebetween. Furthermore, hot melt adhesive is interspersed with theSAP to mutually secure the SAP with the bulky nonwoven substrate and topfabric. The top fabric may be tissue material in preferred embodiments.

In yet another aspect, a method is disclosed for manufacturing anabsorbent composite. The method entails conveying a first substrate of anonwoven material, delivering a mixture of superabsorbent particles(SAP) with hot melt adhesive particles onto the conveyed firstsubstrate, and, as the first substrate with the mixture is conveyed,applying heat to the first substrate, thereby activating the hot meltadhesive particles and bonding the SAP with the hot melt particles andthe first substrate. A second substrate is then applied atop the firstsubstrate and SAP layer bonded therewith.

Other embodiments are disclosed in which aggregates of absorbentparticles are strategically located and/or constituted between a toplayer and a bottom layer, and across the expanse of the composite orcore. By varying the position of the aggregates or the restrictions onthe aggregates, the performance and capabilities of the absorbentcomposite may be managed or influenced. In certain embodiments, theaggregates of absorbent particles are situated in containers or pockets.In further embodiments, the size, spacing, arrangement, and\or geometryor shape of the containers or pockets are specifically provided toachieve certain core fluid handling properties.

In one embodiment, a disposable absorbent article includes a chassisbody defined by a first end margin and a second end marginlongitudinally spaced from the first end margin, the end marginspartially defining front and back waist regions that are fastenableabout a waist of a user. The article further includes a topsheet, abacksheet, and an absorbent composite disposed between the topsheet andbacksheet. The topsheet and backsheet define longitudinal and lateralmargins of the chassis body. The absorbent composite includes a firstfabric and a second fabric bonded to the first fabric. Furthermore,absorbent particles are secured or adhered between the first and secondfabric, wherein the first fabric is intermittently attached to thesecond fabric to define a plurality of containers situated between thefirst fabric and the second fabric and containing an aggregate ofabsorbent particles. The absorbent composite may include regions ofcontainers of absorbent particles aggregates including a primary regionhaving containers of a first size and a secondary region having aplurality of containers of a second size different from the first size.

The present disclosure is of an absorbent composite that, in someembodiments, does not require a SAP layer or SAP constituency with anabsorbent matrix (i.e., free of an absorbent matrix, pulpless) and anovel method of making the absorbent composite. The present documentalso discloses an absorbent article that incorporates the absorbentcomposite. The absorbent composite provides for an absorbent articlethat can be made very thin and pliable, while at the same time retainingenough SAP to provide sufficient absorbency and dry and wet integrity(uniform absorbency). Although using the absorbent composite in a diaperis described, one skilled in the art would readily understand that anabsorbent composite made according to the inventive process may be usedin a wide variety of absorbent products.

The present disclosure is also directed to an improved absorbent articleincorporating the absorbent composite. Further, the present disclosureis directed to methods of manufacturing the absorbent composite or theabsorbent article in which the absorbent composite is employed.

In one example, a method is described for manufacturing a compositesheet, comprising the steps of positioning a first fabric to receiveparticles, depositing particles on the first fabric, applying adhesiveto a second fabric, positioning the second fabric relative to the firstfabric, and forming bond sites that extend between the first and secondfabric. The method may further include an article in which the particlescomprise SAP particles, skin care particles, odor absorbing particles,binder particles, ion exchange particles, and combinations thereof.Still further, the method may include the step of coating the particleswith a hydrophobic material.

The method may include conforming the first fabric to a surface. Thesurface may include recesses that form pockets or containers in thefirst fabric when it is conformed to the surface. The SAP particles maybe guided into the pockets formed in the first fabric. Suction may beused to conform the first fabric to the surface. The adhesive applied tothe second fabric may be applied in a concentration sufficient to securean effective amount of dry particles. That concentration is generallybetween 1 to 100 grams per square meter. More specifically, the adhesivemay be applied in a concentration of between 5 and 75 grams per squaremeter, or even more optimally, between 12 and 50 grams per square meter.The adhesive may be applied in a manner such that the total amount ofadhesive engaging particles is between 1 and 100 grams per square meter.The inventive method may further include a step of applying adhesive tothe first fabric before particles are deposited on the first fabric.

The bond sites suitable for the method may be bond lines, which may becontinuous or discontinuous and may define pockets or other shapes anddesigns. Alternatively, the bond sites may be bond points. The bondsites may be spaced apart and positioned relative to particles and/orarranged to prevent straight line particle migration of more than 2inches, and to present a gap between successive or pairs of bond pointsin an arrangement of bond points encircling a SAP aggregate, whichcommunicates the pockets containing the SAP aggregate with adjacentpockets and/or the rest of the absorbent core.

Alternatively, the method entails positioning a first fabric to receiveparticles, positioning particles on the first fabric, securing theparticles relative to the first fabric, positioning a second fabric overthe particles, and forming bond sites that join the first fabric to thesecond fabric. The bond sites may be discrete points spaced to inhibitthe migration of particles. The bond sites may also be bond lines spacedto inhibit the migration of particles, or bond lines that are connectedto form a single bond line. The bond lines may be arranged to formpockets within which some particles are positioned. The particles may beSAP particles, skin care particles, odor absorbing particles, binderparticles, ion exchange particles, and combinations thereof. Theparticles may be secured to the first fabric with adhesive, thermalplastic, or combinations thereof. In addition to or in the alternative,the particles may be secured to the second fabric with adhesive, thermalplastic, or combinations thereof. Furthermore, shapes may be formed inthe first fabric for receiving particles.

A disposable absorbent article according to the disclosure may comprisea topsheet, a backsheet, and an absorbent core disposed therebetween.The absorbent core is an absorbent composite comprising a first fabric,a second fabric bonded to the first fabric, and particles securedbetween the first and second fabric. The particles may be SAP particles,skin care particles, odor absorbing particles, binder particles, ionexchange particles, combinations thereof, or in preferred embodimentsconsist of SAP.

Alternatively, an absorbent layer may be provided that is supported onthe backsheet, such that a section of the backsheet provides the secondfabric of the absorbent composite. The backsheet may further comprises afirst backsheet layer, a second backsheet layer and SAP particles in aconcentration of about 20 to 650 gsm (preferably greater than 50 gsm insome further embodiments) positioned there between and the second backsheet layer is an SMS having a basis weight in the range of about 10 gsmto 60 gsm. The absorbent layer may be adhered between the first andsecond fabric with an adhesive concentration of between 1 and 100 gramsper square meter. The first fabric may be bonded to the second fabric atdiscrete points, which discrete points may define pockets. Further, thefirst fabric may be bonded to the second fabric along a plurality ofbond lines, which bond lines may define pockets.

The absorbent core may also comprise a first fabric, a second fabric,bond sites at which the first fabric is connected to the second fabric;and an absorbent layer of particles adhered between the first and secondfabric. The particles may be SAP particles and/or other beneficialparticles. The absorbent layer may be supported underneath a section ofthe topsheet, such that the section of topsheet provides the secondfabric of the absorbent composite. The absorbent layer may be supportedon a section of the backsheet, such that the backsheet section providesthe first fabric of the absorbent composite.

In some embodiments, the disposable absorbent article may include aconcentration of SAP particles in the absorbent layer of between about50 and 650 grams per square meter. The SAP particles may also be coatedwith a hydrophobic material to retard the initial receipt of liquid bythe SAP particles in the absorbent layer. The bond sites may define aplurality of continuous lines that inhibit the movement of the SAPparticles of the absorbent layer. The continuous lines may be shaped toform pockets between the first and second fabrics. The bond sites maydefine a plurality of discontinuous lines that inhibit the movement ofthe SAP particles of the absorbent layer. The discontinuous lines may beshaped to form pockets between the first and second fabric.

In the yet another embodiment, the bonds may be positioned alongperiphery of pockets of particles. The bonds may form a pattern such asherringbone, bricklayer, circles, triangles, dots, dashes, rectangles,and combinations thereof. The yet another embodiment may also includeloose particles positioned between the first and second sheets.

The foregoing has outlined rather broadly the features and technicaladvantages of the present disclosure in order that the detaileddescription that follows may be better understood. Additional featuresand advantages will be described hereinafter. It should be appreciatedthat the specific embodiments disclosed may be readily utilized as abasis for modifying or designing other structures for carrying out thesame purposes. It should also be realized that such equivalentconstructions do not depart from the disclosure as set forth in theappended claims. The features which are believed to be characteristic ofthe disclosure, both as to its organization and method of operation,together with further objects and advantages will be better understoodfrom the following description when considered in connection with theaccompanying figures. It is to be expressly understood, however, thateach of the figures is provided for the purpose of illustration anddescription only and is not intended as a definition of the limits ofthe present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

This patent or patent application contains at least one drawing executedin color. Copies of this patent or patent application publication withcolor drawing(s) will be provided by the Office upon request and paymentof the necessary fee.

For a more complete understanding of the present disclosure, referenceis now made to the following descriptions taken in conjunction with theaccompanying drawing, in which:

FIG. 1 is a schematic of one embodiment of a method of making anabsorbent composite using calendar rolls;

FIG. 2 is a schematic of another embodiment of a method of making theinventive absorbent composite using calendar rolls;

FIG. 3 is a schematic of the method shown in FIG. 1 with an additionalenergy source;

FIG. 4 is a variation of the method shown in FIG. 1 that uses ultrasonicbonding techniques instead of calendar rolls;

FIG. 5 is a variation of the method shown in FIG. 2 that uses ultrasonicbonding techniques instead of calendar rolls;

FIGS. 6A-6Q are illustrations of various potential bonding patterns thatmay be used in the method and absorbent article;

FIG. 7 is a cross sectional illustration of a pockets formed by themethod and utilized in the absorbent article;

FIG. 8 is a perspective view of a disposable absorbent article embodyingthe absorbent composite;

FIG. 9 is a top plan view of the disposable absorbent article of FIG. 8in a flat and extended condition;

FIG. 10 is an exploded view of the disposable article of FIG. 8;

FIG. 11 is a partial cross-sectional view of an absorbent core utilizingthe absorbent composite and employed by an absorbent article;

FIG. 12 is partial cross-sectional view of an absorbent core utilizingan alternative embodiment of the inventive absorbent composite andemployed by an alternative absorbent article;

FIG. 13 is a cross-sectional view of an absorbent article employing inthe leg cuffs an absorbent composite;

FIG. 14 is a cross-sectional view of an absorbent article employing inthe leg cuffs a saturated absorbent composite;

FIGS. 15A-15D are simplified illustrations of an absorbent compositeaccording to the present disclosure, with particular attentions to anarrangement of aggregates of absorbent particles across the composite;

FIG. 16A is a simplified illustration of a prior art SAP sandwich;

FIG. 16B is a simplified illustration of an SAP structure (sandwich) inaccordance with the present disclosure;

FIGS. 17A-17D are simplified illustrations in cross-sectional view ofpockets and fluid properties characterizing the arrangement of pockets,in accordance with the disclosure;

FIG. 18A is a simplified schematic of a process of making an absorbentcomposite according to the disclosure;

FIGS. 18B-18C are illustrations or photographs of exemplary componentsof the process described in respect to FIG. 18A;

FIG. 19 is a simplified cross-sectional view representing an absorbentcomposite in accordance with the process of FIG. 18A;

FIG. 20A is a simplified cross-sectional view across a lateralcenterline of a disposable absorbent article employing an absorbent corelaminate in accordance with a preferred embodiment of the disclosure;

FIG. 20B is a simplified cross-sectional view across a longitudinalcenterline of a disposable absorbent article employing an absorbent corelaminate in accordance with a preferred embodiment of the disclosure;

FIG. 20C is a simplified cross-sectional view of an absorbent compositein the absorbent core laminate of FIGS. 20A and 20B;

FIG. 21 is an exploded view of an absorbent core laminate according toan embodiment of the disclosure;

FIGS. 22A-22C are exploded view of various stages of manufacturing thelaminate in FIG. 21;

FIG. 23 is a top perspective view of an embossed absorbent core laminateaccording to an embodiment of the disclosure;

FIG. 24 is a plan view of an exemplary absorbent core laminate employingbond points, according to an embodiment of the disclosure;

FIG. 25 is a plan view of an absorbent core laminate according to analternate embodiment of the disclosure;

FIG. 26 is an exploded view of an absorbent core laminate according toan alternate embodiment of the disclosure;

FIG. 27 is simplified illustration of a stage in the manufacture of anabsorbent core laminate according to an embodiment of the disclosure;

FIG. 28 is a plan view of a disposable absorbent article employing anabsorbent core laminate, according to a preferred embodiment of thedisclosure;

FIG. 29 is a simplified illustration in cross-sectional view of anabsorbent composite according to a preferred embodiment of thedisclosure; and

FIG. 30 is a simplified illustration in partial cross-sectional view ofa bulky nonwoven layer point bonded in an absorbent composite accordingto the disclosure.

FIG. 31 is a Table of web thickness (in microns) vs. basic weight anddensity; and

FIG. 32 is a Table of pore diameter (in microns) vs. density at a givenfiber size and fiber density.

DETAILED DESCRIPTION

Upon review of the detailed description and the accompanying drawingsprovided herein, it will be apparent to one of ordinary skill in the artthat an absorbent composite made according to the present disclosure maybe used in disposable absorbent articles, and more particularly, indisposable absorbent articles, such as diapers, training pants or otherincontinence products. Accordingly, the present disclosure shall not belimited to the structures and processes specifically described andillustrated herein, although the following description is particularlydirected to an absorbent composite that is used in a disposable diaper.The term “absorbent article” or “absorbent garment” with which thepresent disclosure is associated, includes various types of disposablearticles and garments which are placed against or in proximity to thebody of the wearer so as to absorb and contain various bodily exudates,bodily fluid, or biofluid.

Perhaps to gain a better understanding and appreciation of theparticular contributions and improvements which are introduced in thepresent disclosure, reference may be first made to the improvementsearlier disclosed in U.S. Pat. No. 8,148,598. These earlier improvementsare described in respect to FIGS. 1-14. Some of the teachings andsuggestions therein may, in addition to serving as background knowledgein the art, translate to certain specific embodiments of the presentdisclosure (which will become apparent to one skilled in the relevantart given the present disclosure).

In FIG. 1, a fabric 125 is shown as it is dispensed from roll 120 andcarried along a production line on a conveyer belt 100 or other surface.The fabric 125 may be thermal plastic material that may be a woven,nonwoven, film, or a combination thereof. The fabric 125 is secured tothe conveyor belt 100 (or other means) by a vacuum system 110. Thevacuum system 110 serves to confirm the fabric 125 to the conveyor belt100 (or other means).

In one embodiment, the surface of the conveyor belt 100 has recessedportions that form cups in the fabric 125 as the fabric is pulledagainst the surface of the conveyor belt 100. The surface of theconveyor belt 100 is not limited to constructions that form cups in thefabric but, instead, may be configured with a number of differentsurface shapes and sizes. Examples include ridges, raised shapes, andholes. In addition, the surface shapes may be distributed uniformly ornon-uniformly across the width and length of the conveyor belt.Alternatively, the conveyor belt 100 may be flat. In applications inwhich the conveyor belt 100 has holes or other similar constructions,the depth of the pockets formed in the fabric 125 may be varied by theforce of the vacuum system 110, the elasticity of the fabric 125, or acombination thereof. Additionally, heat may be used to increase theelasticity of the fabric 125 as the fabric is pulled against the surfaceof the conveyor belt 100. Heat may be applied to the fabric by way of aheated conveyor belt or any other means known in the art. The vacuum 110may be applied uniformly across the surface of the conveyor belt 100 orat selected locations. For example, in a configuration in which thesurface of conveyor belt 100 has depressions, vacuum may be applied onlyat the depressions.

The SAP particles 135 are then deposited on the fabric 125 by SAPdispenser 130. The SAP dispenser 130 may be configured to position SAPparticles in their desired position on the first fabric or may beconfigured merely to deposit SAP particles on the first fabric, whereinthe SAP particles are position by another means. One skilled the artunderstands that multiple SAP dispensers 130 may be used. The SAPparticles 135 may be deposited, positioned, or both on the fabric 125 bywind or other known methods. Alternatively, the conveyor belt shown inFIG. 1 may be inverted so that the vacuum system 110 applies suctionfrom above. In such a configuration, the fabric 125 is carried over asupply of SAP particles 135 and the SAP particles are held onto thesurface of fabric 125 by vacuum system 110. In alternative embodiments,SAP dispenser 130 may include skin care particles such as ion exchangeresins, deodorant, anti-microbial agents, binder particles, or otherbeneficial particles. Further, although the preferred embodiment isdirected to SAP particles, the methods disclose herein can be used withany combination of the above referenced particles, includingcombinations that do not include SAP. Alternatively, separate dispensersadvantageously positioned along the production line (not shown) may beused to deposit different types of particles such as, for example, skincare particles.

The SAP particles 135 are positioned and concentrated on the fabric 125according to a number of alternative methods. In one embodiment, thevacuum system 110 and fabric 125 may be configured to allow the vacuumsystem 110 to pull the SAP particles 135 against the surface of thefabric 125 uniformly or in particular areas. In another embodiment, theshape of the fabric 125 guides the SAP particles 135 into position. Forexample, when the fabric 125 is shaped to form pockets, the SAPparticles 135 roll into the pockets as a result of the vacuum system110, the vibration of the conveyor belt, air flow, the angle of theconveyor belt, or combinations thereof. Alternatively, the SAPdispenser(s) 130 may be positioned and controlled to dispense SAPparticles 135 strategically across the surface of fabric 125, whichstrategic positioning includes but is not limited to alignment ornonalignment with the machine direction, offset, or randomly. Further,SAP may be positioned such that there are zones without SAP particles.Still further, SAP particles may be positioned using adhesive such as byapplying adhesive to specific locations on a surface, depositing SAPparticles on the surface. Still further, SAP particles may be positionedon both fabrics 125 and 155.

Once SAP particles have been deposited and positioned on fabric 125, asecond fabric 155 is introduced into the production line from roll 150.The second fabric 155 may be selected from a variety of materialsincluding spun-bonded thermoplastic or similar woven or nonwovenmaterial, film, or combinations thereof.

The adhesive 145 is applied to the SAP particles 135 in a number ofways. FIG. 1 shows the adhesive 145 applied to the fabric 155.Alternatively, the adhesive 145 may be applied to the fabric 125 and SAPparticles 135, fabric 125 before the SAP particles 135 are deposited onthe fabric 125, or directly to the SAP particles before they aredeposited on the fabric 125. In still another embodiment, the adhesive145 is applied at the point where fabrics 125 and 155 are jointedtogether. In still another embodiment, multiple coats of adhesive areapplied. For example, adhesive 145 may be applied to the fabric 125before the SAP particles 135 are deposited, to the SAP particles 135after they have been positioned, to the fabric 155, or a combinationthereof. Alternatively or in addition to the above embodiments, binderparticles may be mixed with the SAP particles 135. Additionally, theadhesive may be applied uniformly, randomly, or in a specific pattern,depending the desired absorbent properties of the finished composite.

The adhesive is applied according to a number of methods know to thoseskilled in the art. For example, the adhesive may be sprayed, rolled, orspun onto the surface of fabric 155. The adhesive may be hydrophobic,hydrophilic, biodegradable, bioderived, or combinations thereof. Thepreferred adhesive is hydrophilic. The concentration of adhesive in acoat varies between 0.5 and 100 grams per square meter (“GSM”).Optimally, the concentration is between 1 and 25 GSM. In a preferredembodiment, the concentration is between 2 and 10 GSM. Additionally,enough adhesive should be applied to cover at least 25% of the targetedarea.

Fabrics 125 and 155 are then bonded together. FIG. 1 shows a thermalbonding system in which calendar rolls 160 and 170 are used. However,other bonding systems/methods may be used. For example, the ultrasonicbonding system of FIGS. 4 and 5 may be used. Adhesive 145 retains theSAP particles 135 in a relatively fixed position with respect to thefabrics during the bonding process and subsequent to the bondingprocess. The bond pattern may be aligned with the distribution of theSAP particles 135. Alternatively, the bond pattern may not be alignedwith the distribution of the SAP particles 135. In such embodiments, thebonding equipment may be adapted to nudge the SAP particles 135 asideprior to bonding or to bond through the SAP particles 135. Theseembodiments eliminate the need to synchronize the bond points with thedistribution of SAP particles.

Fabrics 155 and 125 are shown as two materials. However, one skilled inthe art understands that the fabrics may actually be part of the samematerial. In such a configuration, the unitary fabric is folded to coverthe SAP particles. Alternatively, the edges of fabric 125 may be foldedprior to applying the second fabric 155. In embodiments in which fabrics125 and 155 are separate, fabrics 125 and 155 may be the same or adifferent material. Additionally, fabric 155 may be sized to coverspecific areas, such as the center section, of fabric 125.

Once the fabrics have been bonded together, the absorbent composite 195is collected on rewinder 200.

In a method illustrated in FIG. 2, the fabric 125 is transported alongthe conveyer belt 100. As fabric 125 is transported along the conveyerbelt 100, a thin coat of adhesive 145 is applied to fabric 125. As withthe method of FIG. 1, the adhesive may be applied uniformly, randomly,or in a specific pattern, depending the desired absorbent properties ofthe finished composite. Although the adhesive 145 is shown being appliedbefore the SAP Particles 135 are deposited, alternate embodiments areenvisioned. For example, the adhesive may be applied according to theembodiments described with respect to FIG. 1.

Following the application of the adhesive, SAP particles 135 aredeposited and positioned on the fabric 125. The SAP particles 135 may bedeposited directly on fabric 125, as shown in FIG. 2, or indirectly,such as by air flow blowing SAP particles across fabric 125. The weightof the SAP particles aids in securing the fabric 125 to the conveyorbelt 100. Additionally, the SAP particles may be positioned in a mannersimilar to that disclosed for FIG. 1.

A second fabric 155 is then fed into the production line from roll 150.The second fabric is positioned to cover the SAP particles 135. Theadhesive 145 prevents the SAP particles from moving freely between thetwo fabrics. The resulting sandwiched construction is then transportedto the calendar rolls for thermal bonding. As described with respect toFIG. 1, the bond pattern may be aligned or not aligned with the SAPparticles 135. The absorbent composite 195 is then collected by rewinder200. As described with respect to FIG. 1, fabrics 125 and 155 may bepart of a single sheet. Additionally, the fabrics may be folded in themanner described for FIG. 1. In another embodiment, the fabric 125 maybe coated with adhesive and pressed on a supply of SAP particles.

FIG. 3 is similar to FIGS. 1 and 2, except that an energy source 900such as an oven or microwave generator is positioned along the assemblyline. The energy source applies heat and or radiation 910 that can beused to melt thermal plastic binder. The amount of heat may also beregulated to melt specific types of particles or fibers, specificsections of the fabrics, or only the outer layers of particles/binder.

FIGS. 4 and 5 are similar to FIGS. 1 and 2, except that the fabrics arebonded together using ultrasonic bonds. FIGS. 4 and 5 show an ultrasonicbonding system (210 a and 210 b). It is readily understood that FIGS.1-5 show different embodiments of the novel method and that aspects ofthe various methods may be advantageously combined depending on theneed. Important to all combinations, however, is the amount of adhesive145, binder particles, or combinations thereof applied to the SAPparticles 135 and the strength of the bonds. As noted with respect toFIG. 1, the optimal concentration of adhesive is between 12 and 50 GSM,though other concentrations are acceptable. In all embodiments, it isimportant that the concentration of adhesive 145 be high enough toinhibit the migration of SAP particles 135. The concentration should notbe so high, however, that it coats the SAP particles 135 and reduces SAPswelling. The adhesive should only inhibit the migration of enough SAPparticles 135 to assure uniform absorbency. Although not shown, oneskilled in the art understands that the energy source 900 shown in FIG.3 can also be applied in the configurations shown in FIGS. 2, 4 and 5.

FIG. 6 (a) through (q) show various bonding patterns contemplated by themethod. The bonding patterns may completely enclose an area, partiallyenclose an area, or provide local bonding zones. The lines and pointsindicate the bond sites. The solid lines depict bond lines. The bondlines may form open shapes or enclosed shapes, such as can be found inexamples (a) and (c), which depict continuous bond lines that completelyenclose pockets of SAP particles 135 or, as in example (g), separatedistinct regions of the absorbent composite. The dashed lines, such ascan be found in examples (b) and (m), are discontinuous bond pattersthat do not completely enclose pockets of SAP particles 135. In theseconfigurations, the migration of dry SAP particles is inhibited by theadhesive and continuous or discontinuous bond patters. Discontinuouspond patters may be substituted for continuous bond patterns and viseversa. Further, though the FIG. 6 shows either continuous ordiscontinuous bond patters, combinations of discontinuous and continuousbond patters may be used.

FIG. 7 shows a partial cross-section of an absorbent composite 195. FIG.7 shows how bonds 192 may act to separate pockets of SAP particles 135.As noted with respect to the bonding pattern, SAP particles 135 may beentirely enclosed in pockets defined by the bonding pattern, partiallyenclosed in pockets defined by the bonding pattern or merely inhibitedby the bonding pattern. Inhibited in this context means the SAPparticles 135 cannot move directly from one area of the core to anotherarea, but instead, must move around bond sites.

Notably, multiple functions or advantageous properties are obtained inthe absorbent composite by varying the amount of SAP particles, the typeand number of fabrics used, and construction variables such as, theratio of SAP to adhesive, and applying the absorbent composite atvarious locations in the article. Such manufacturing and designtechniques may be incorporated into structural designs and methods ofthe present disclosure.

Additionally, one skilled in the art understands that the process forconstructing a single absorbent composite described above may bemodified to produce a multiple, laminated absorbent composite. Instructures comprising multiple layers, the layers may be sheets ofabsorbent composite 195 that are laminated together to form a singlestructure or alternating layers of fabric and SAP particles 135 thatform a single structure. One skilled in the art understands thatalternating layers may be achieved by applying adhesive to the top offabric 155 (FIG. 1), applying a second layer of SAP particles 135, and athird fabric (not shown). Similarly, additionally layers may be added,limited only by the maximum thickness suitable for the bonding process.

The SAP particles 135 may be coated with a miscible, hydrophobicmaterial. The coating acts as a barrier or membrane that initially slowsthe liquid uptake, thereby saving SAP capacity for additional orsecondary discharges. In this regard, the coating evens out theabsorbency rates between discharges. In the processes shown in FIGS. 1to 5, the coating may be applied prior to the adhesive 145 beingapplied, after the adhesive 145 is applied, or at the same time.Alternatively, the adhesive may be mixed with the coating material.

In one example, a light coating of mineral oil is applied over the SAPparticles 135. The coating retards the initial uptake by the SAPparticles and allows more time for the liquid to spread out in thearticle. Preferably, the mineral oil is applied at a concentration ofabout 0.00001 grams per gram of SAP to about 0.1 grams per gram of SAP(depending on the particular product design). Alternatively, the mineraloil may be applied in specific target zones. In this way, the receivedliquid is encouraged to initially spread to uncoated areas before thecoated areas are activated and begin to swell.

An absorbent composite manufactured by the above-described process maybe used for a disposable absorbent article or as one or more of thecomponents of a disposable absorbent article. The components of anabsorbent article include the backsheet, topsheet, absorbent core,containment walls or cuffs (including leg gathers), backsheet/absorbentcore composite, topsheet/absorbent composite, and combinations thereof.Such constructions are described below in more detail.

FIG. 8 is a perspective view of a disposable absorbent article in theform of a diaper 10. Diaper 10 comprises a topsheet 50, a backsheet 60,and an absorbent core (not shown). The diaper further comprisesupstanding barrier cuffs 34 which extend longitudinally along the diaperand are elasticized to conform to the buttocks of the wearer.Additionally, the diaper includes an elastic band 52 and fasteningelements 26. Element 26, in use, extends to and engages thecorresponding opposing end of the diaper to secure the diaper about thewearer.

FIG. 9 illustrates a composite web structure of the diaper 10 of FIG. 8in a generally flat and unfolded configuration. As will be explainedfurther below, the web structure may be subsequently trimmed, folded,sealed, welded and/or otherwise manipulated to form a disposable diaper10 in a finished or final form. To facilitate description of the diaper10, the description refers to a longitudinally extending axis AA, alaterally extending central axis BB, a pair of longitudinally extendingside edges 90, and a pair of end edges 92 which extend between sideedges 90. Along the longitudinal axis AA, the diaper 10 includes a firstend region or front waist region 12, a second end region or back waistregion 14, and a crotch region 16 disposed therebetween. Each of thefront and back waist regions 12, 14 is characterized by a pair of earregions or ears 18, which are located on either side of a central bodyportion 20 and extend laterally from the side edges 90. A fasteningstructure 26 (e.g., a conventional tape fastener) is affixed to each ofthe ears 18 along the back waist region 14 of diaper 10.

When the diaper 10 is worn about the waist, the front waist region 12 isfitted adjacent the front waist area of the wearer, the back waistregion 14 is fitted adjacent the back waist area, and the crotch region16 fits about and underneath the crotch area. To properly secure thediaper 10 to the wearer, the ears 18 of the back waist region 14 arebrought around the waist of the wearer and toward the front and intoalignment with the ears 18 of the front waist region 12. The securingsurface may be located on or provided by the interior or exteriorsurface of the front waist region 12. Alternatively, the fasteners 26may be located on the ears 18 of the front waist region 12 and madesecurable to the ears 18 of the back waist region 14.

FIG. 10 is an exploded view of the diaper of FIGS. 8 and 9. A suitablediaper structure typically employs at least three layers. These threelayers include a backsheet 60, an absorbent core 46, and a topsheet 50.The diaper structure mayor may not contain a pair of containment wallsor leg cuffs 34 disposed upwardly from the topsheet 50 and preferablyequipped at least with one or more spaced apart, longitudinally elasticmembers 38. It will be shown below that any of these diaper elements ora combination of these elements may be constructed with or using theabsorbent composite 195. Additionally, an acquisition layer 48 could beadded to improve performance.

Backsheet

As mentioned above, the diaper 10 employs a backsheet 60 that covers thecore 46 and preferably extends beyond the core 46 toward the side edges90 and end edges 92 of the diaper 10. In one aspect of the invention,the backsheet 60 is constructed from a single-layered material sheet ofabsorbent composite 195. In such a configuration, fabric 125 ispositioned as an outer surface of the backsheet 60.

Additionally, an alternative structure could be used for gel blocking.For an application using gel blocking, a backsheet of the inventivedisposable absorbent article is relatively thin and provides improvedflexibility. When dry, the backsheet is soft and breathable, but uponwetting, a thin, gel blocked layer is formed (i.e., on the inner surfaceof the backsheet) which renders the backsheet substantially liquidimpervious. The gel blocked layer is formed by the swelling of the SAPparticles 135.

Topsheet

Similarly, the absorbent composite 195 may be utilized with or as thetopsheet of an absorbent garment. The topsheet 50 is preferably soft,compliant, exhibits good strikethrough and a reduced tendency to rewetfrom a liquid pervious material. The topsheet 50 is placed in closeproximity to the skin of the wearer when the diaper 10 is worn. In thisway, such a topsheet 50 permits bodily discharges to rapidly penetrateit so as to flow toward the core 46 more quickly, but not allowing suchdischarges to flow back through the topsheet 50. The topsheet 50 may beconstructed from anyone of a wide range of liquid and vapor permeablehydrophilic materials. The surface(s) of the topsheet may be treatedwith a surfactant so as to facilitate liquid transfer therethrough,especially at a central zone or area of the topsheet located over thecore and an inner surface of the core. The topsheet may also be coatedwith a substance having rash preventing or rash reducing properties(e.g., aloe vera).

In one example, the topsheet 50 is formed from an absorbent composite195 that covers substantially the entire area of the disposal absorbentarticle 10, including substantially all of the front waist region 12,back waist region 14, and crotch region 16. Further, the ear layer ofthe inner region 18 is formed from the same single topsheet materialand, thus, may be referred to as being unitary with the topsheet 50 informing lateral extensions of the topsheet material. Alternatively, thetopsheet 50 may be formed from multiple different materials which varyacross the width of the topsheet 50. Such a multiple piece design allowsfor creation of preferred properties and different zones of thetopsheet.

Absorbent Core

In addition to or as an alternative to the above examples, the absorbentcore of the disposable absorbent article may be constructed from theabsorbent composite 195, laminated layers of absorbent composite 195(not shown) or multiple layers of SAP particles 135 and fabric. FIGS. 11and 12 depict cross sectional views of alternating layers of SAPparticles 135 and fabric that form a multi layered absorbent composite700 and 900, respectively. As shown in these drawings, the core 46 maybe comprised of distinct layers of SAP particles 135 (710 and 910). Thelayers may be uniform or non-uniform, depending on the intendedapplication. In the non-uniform multi layered absorbent composite 900,the concentration of SAP particles 135 may vary within a given layer,between layers, or combinations thereof.

FIG. 11 depicts a composite structure 700 in which SAP particle layers710 and fabric layers 720 are alternated to form the completed compositestructure 700. The layered design can also be constructed by bondingtogether sheets of absorbent composite, folding a unitary sheet ofabsorbent composite, or constructing absorbent composites with multiplelayers during the manufacturing process. In folded applications, thecomposite fold may be a C-fold, Z-fold, V-fold, W-fold or combinationsthereof. Further, the folds may be open, closed, or overlapping.

FIG. 12 depicts multi layers absorbent composite 900. As shown in FIG.12, high concentrations areas of SAP particles 910 may be strategicallypositioned to provide additional absorbency in specific regions such asthe crotch of an absorbent article. One skilled in the art understandsthat the high concentration areas may be offset to control the amountand direction of liquid penetration. Additionally, the layer with zonesof high concentrations may be combined with layers of substantiallyuniform layers. Alternatively, the high SAP concentration areas can beformed by positioning multiple layers of absorbent core.

The core may be configured to extend substantially the full lengthand/or width of the disposable absorbent article. Preferably, however,the core is disposed or is otherwise concentrated at the crotch regionof the article. In various embodiments, the core extends to the edges ofthe article and the SAP particles 135 are concentrated in the crotchregion or another target zone of the article. In still anotherembodiment, the particles can be a combination of SAP particles, skincare particles such as ion exchange resins, deodorant, anti-microbialagents, binder particles, or other beneficial particles.

Containment Walls

Now turning to FIGS. 13 and 14, the disposable absorbent article 10utilizes a pair of containment walls or cuffs 34 which employ theabsorbent composite 195. Each containment wall 34 is a longitudinallyextending wall structure preferably positioned on each side of the core46 and spaced laterally from the longitudinal center. The longitudinalends of the walls 34 may be attached, for example, to the topsheet 50 inthe front and rear waist regions 12 and 14. Preferably, the ends of thecontainment wall 34 are tacked down inwardly and attached, for example,by adhesive to the web structure. Such a construction effectively biasesthe containment wall 34 inwardly and is generally considered to causecontainment wall 34 to exhibit improved leakage prevention properties.

FIG. 13 provides a cross-sectional view of a diaper 10. The diaper 10includes backsheet 60, absorbent core 46, acquisition layer 48, andtopsheet 50. As shown in FIG. 13, the core is an absorbent composite195. The diaper 10 also includes a pair of containment walls or cuffs 34which are formed by folding the topsheet 50 and wrapping it about theends of the absorbent composite 195. Alternatively, the absorbentcomposite 195 in the cuffs 34 may be distinct from the absorbent core46.

Preferably, the containment walls 34 are equipped with elastic members38, which extend along a substantial length of the containment walls 34.In a common application, the elastic members 38 are placed within thecontainment walls 34, preferably at the top of the containment walls 34while in a stretched condition and the glued to the containment walls atleast at their ends. When released or otherwise allowed relaxing, theelastic members 38 retract inwardly. When the article 10 is worn, theelastic members 38 function to contract the containment walls 34 aboutthe buttocks and the thighs of the user in a manner, which effects aseal between the article 10, the buttocks and the thighs. The core 46may be a single sheet of absorbent composite 195 or multilayered, asdescribed above.

FIG. 13 depicts the configuration of the containment walls 34 when it issoft and dry. FIG. 14, on the other hand, depicts the containment wallsafter wetting, in which the absorbent composite 195 has swollen todispose the containment walls 34 in a resiliently, erect position.Unlike traditional leg cuffs in the prior art, the resiliently erectcontainment walls 34 resists flattening (e.g., when the wearer sitsdown) and, thereby, ensures leakage prevention, especially of explosive,liquefied bowel movements and rapid discharges of urine.

Optional Layers

The disposable absorbent article may employ additional layers includingan acquisition layer or surge layer 48, preferably situated between thetopsheet and the core (e.g., FIG. 10). One function of such anacquisition layer is to spread out or disperse liquid flow so thatliquid is distributed more evenly over the core surface. This serves toslow down the flow so that the liquid has adequate time to be absorbedby the core. The acquisition layer also serves to prevent the core frombeing saturated locally, while a substantial remainder of the core isnot absorbing any liquid.

Tape Tabs

The disposable absorbent article must be secured to the wearer. This ismost important with respect to diapers since diapers are not pulled upby the wearer, like training pants or incontinent briefs, but arefastened around the wearer. Securing elements compliment the elasticmembers by effecting a quasi-seal between the wearer and the waistbandand leg cuffs, so that liquid is contained within the article which isthen absorbed; in other words, so that it does not leak through gapsbetween the wearer and the edge of the article. The securing elementsmay be adhesive, mechanical fasteners hook and loop features, orconceivably strings, i.e., anything that will secure one end of thearticle to the longitudinally opposite end. The securing elements mayalso be co-adhesive such that they adhere to each other but not othermaterials.

In the examples shown in the Figures (see, e.g., FIG. 10), the article10 is affixed to the wearer by tape fasteners 26 which are permanentlyaffixed to (e.g., sewn directly into) the backsheet 60. Tape fasteners26 are contacted with the transversely opposite ear 22 extending fromthe backsheet, where they remain affixed due to adhesive compoundapplied to the fasteners 26. Alternatively, the article 10 may betraining pants, pull-on diapers, and the like. In this configuration,the article 10 mayor may not have tape fasteners 26.

Waistband

Waistbands employing elastic members 52 are positioned along thetransverse portion of the article 10 so that when worn, the waistbandsare positioned along the waist of the wearer. Generally, the waistbandpreferably creates a quasi-seal against the waist (transverse elasticmembers 52) so that liquid waste does not leak from the regions betweenthe waist elastic and the waist of the wearer. The quasi-seal issignificant because, although the liquid may be eventually absorbed byfiller material, the assault of liquid by the wearer may overwhelm theabsorption rate capacity of the filler material. Hence, the waistbandscontain the liquid while it is being absorbed. Secondly, the waistbandsmay have a capacity to absorb liquid (see, e.g., U.S. Pat. No.5,601,544, which is hereby incorporated by reference).

Aggregate (and Embossing) Patterns and Material Selection for FlufflessAbsorbent Composites

The simplified illustrations of FIGS. 15A-15D present absorbentcomposites 510 with particularly advantageous arrangements of aggregates512 of absorbent particles, according to the present disclosure (withlike reference numerals used to indicate like elements). Referring firstto FIG. 15A, each of the aggregates on the absorbent composite 510 isrepresented by the diamond-shaped enclosure 514 in the pattern. Inpreferred embodiments, SAP is employed as the absorbent particles in theaggregates. Furthermore, SAP aggregates in each of FIGS. 15A-15D arepreferably maintained in place and stabilized by physical entrapments orcontainers provided by the engagement of a first fabric disposedgenerally above the SAP aggregate with a second fabric disposedgenerally beneath the SAP aggregate. Thus, in an alternative view ofFIG. 15A, the diamond units represent the outline of the containers orpockets, reflecting in particular embodiments, the engagement of the topfabric with the bottom fabric, as previously described herein.

As described previously, the absorbent performance of the SAP can beaffected by the size and structure of the container. As SAP becomes moresaturated, its permeability is reduced. Water cannot pass through theSAP particle due to the high level of water already contained within theSAP particle and eventually the SAP can completely halt the passage offurther fluid through it. This is known as gel blocking. Also, as SAPbecomes more saturated, it swells and its volume increases. By confiningthe SAP in a small container of fixed volume it is possible to restrictthe swelling of the SAP and prevent it from reaching its highestsaturation levels (and, by consequence, stop the SAP from reaching itslowest levels of permeability). The degree to which the SAP particle isrestricted depends on a number of factors, including: the nature andsize of the container, the size and frequency of any breaks in thecontainer (e.g., along the side walls), the amount of SAP disposed inthe container, and the amount of fluid absorbed by the SAP. Further, theperformance properties of SAP are affected by its degree of saturation.Specifically, absorbent composite properties such as permeability,absorption rate, capillary pressure (arising from the void space in thecomposite) will vary significantly as the SAP changes from dry to fullysaturated. In accordance with a method of the present disclosure, targetor optimal performance of the SAP may be achieved by changing the sizeof the container and/or the SAP concentration so as to physicallyconstrain the swelling of the SAP and limit the maximum saturation pointof the SAP. By incorporating these physical features, preferred levelsof permeability or a preferred absorption property may be achieved intarget regions of the absorbent core. Thus, by playing with the twovariables of pocket size and the amount of SAP in the pocket, theminimum permeability of that container or pocket may be “set”. Pocketsin some regions of the diaper may be prevented from gel blocking and thepermeability of that region of the core may be optimized. A gradient ofpocket size may also be established to obtain maximum flow andutilization of the absorbent core. This gradient will be radiate fromthe target zone towards the ends or sides of the diaper.

The various arrangements of containers or pockets also promote SAP andcore utilization and prevent fluid from bypassing the containers.Ideally, fluid should leak or flow from container to container as theSAP reaches the optimum level of saturation which is set either by theproperties of the SAP or the volume of the pocket into which it isexpanding. Applicants contemplate that, in some of the previouslydescribed composites or arrangements of pockets (see FIG. 6), there maybe a tendency for fluid to leak between the pockets. That is the fluidruns along the channels formed by embossing lines and does not enter thecore. To mitigate this tendency, arrangements or patterns for thecontainers are preferably ones that minimize or eliminate short anddirect routes (as may be established along embossing lines) of fluidflow from the core center to the side margins of the core (at endedges). To illustrate, containers or pockets shaped as diamonds arepreferred to ones formed in squares or rectangles, because the diagonallines or channels formed by the diamond containers are longer and morecircuitous. Circles are also effective if packed in a way that does notpresent channels that flow quickly to the edge. In more preferredarrangements, fluid flow is forced to change directions one or moretimes before flowing through the side of the diaper.

An absorbent core for a baby diaper or adult incontinence product isrequired to absorb fluid quickly, in an anatomically aligned region ofthe core, absorb all the fluid without leaking at the sides or ends ofthe product and hold on to that fluid without wetting the user's skinparticularly when under the pressure caused by the user's bodyweight.This present disclosure accomplishes that by providing regions of thecore having different performance parameters defined by the size of thecontainers retaining the SAP, as well as the arrangement of thecontainers. Thus, a core may be designed to attain optimized performancecharacteristics by changing the size of the pocket and/or theconcentration of SAP within that pocket.

In certain arrangements shown here, design features are combined toprovide a core that is less likely to leak, absorbs wetness fast, andprovides a dry, comfortable feeling for the user. At the crotch regionof the core, the container size and SAP loading are optimized to providean open structure, with high permeability, resulting in fast acquisitionor distribution of fluid away from the point of insult and away from theuser's skin. Permeability is maintained even when the SAP is swollen dueto the physical constraints of the container restricting furtherswelling. This allows the liquid to spread more efficiently toward theregions further away from the target zone (crotch area), and contributesto better performance and utilization of the absorbent core. At regionsaway from the crotch region, such as regions proximate the periphery ofthe core and beyond, permeability is reduced to slow down the fluid.Absorption capacity is increased by the larger pockets allowing the SAPto swell more fully and hold on to more fluid.

In FIG. 15A, large diamond shaped containers or pockets 514 of absorbentparticles aggregate 522 are present in a region anatomically alignedwith the point of insult. The containers then gradually reduce in sizetoward the sides and front and rear margins or edges of the core 510.There are three distinct regions of containers. In the crotch region“A”, large diamond shaped pockets are provided. Adjacent and surroundingthe crotch region is an intermediate region “B” of pockets of smallersize than those in the crotch region (A). Among other things, thesmaller pockets of this intermediate region (B) present breaks in thepotential fluid flow around the SAP aggregates and along embossinglines. As described previously, the presentation of such barriers todirect escape of fluid flow through the side margins prevents leakageand promote utilization of the SAP aggregates. Finally, a third region“C” of pockets is present near each of the end edges of the core 510populated by even smaller sized pockets of SAP aggregates.

FIG. 15B illustrates a second exemplary arrangements of SAP aggregates522 and pockets 514. In this example, small, diamond shaped pockets 522are disposed in the region anatomically aligned with the point of fluidinsults. The pockets then gradually increase in size in regions disposedtoward the sides and front and rear edges of the core. The twoarrangements (in FIGS. 15A and 15B) provide alternative ways ofstructuring the expected flow gradient and as well, handling of theliquid insults. The absorbent composite and arrangement of pockets inFIG. 15A may provide for a center region with a larger capacityinitially, but which, over time, will redistribute liquid in its voidvolume, or from subsequent liquid insults, to smaller adjacent pocketsor cells. With the pattern of FIG. 15B, the center region may beequipped with smaller capacity initially, which will cause the liquid totravel to larger cells. It may also generate a surface topography thatprevents leakage from the sides and ends of the diaper, i.e., “dams”will be created that intercept and absorb surface flow.

FIGS. 15C and 15D provide alternate arrangements wherein circularpockets for SAP aggregates are employed. In FIG. 15C, large, circularshaped pockets are present in a region anatomically aligned with thepoint of insult. The pockets 534 gradually reduce in size toward thesides and front and rear edges of the core 530. The pattern is similarto that employed in FIG. 15A but with circular pockets rather thandiamond-shaped ones. Many of the characteristics of the arrangement inFIG. 15A translate to the design of FIG. 15C.

However, unlike a diamond shaped pocket, it is not possible to produce aperfectly close packed pattern with circular shaped pockets and theresulting space between the circular pockets could be disposed in anumber of ways. It is envisaged that the space between the circularpockets could either be completely embossed (i.e., have large embossed,thermally bonded regions between the pockets), partially embossed or notembossed. The spaces could also contain SAP or be free of SAP.

FIG. 15D illustrates a further embodiment of the present invention, witha pattern analogous to that found in FIG. 15B. In this example, small,circular shaped pockets 544 are disposed in the region anatomicallyaligned with the point of fluid insults. The pockets 544 graduallyincrease in size in regions disposed towards the sides and front andrear edges of the core. Again the space between the pockets 544 could beutilized in a number of ways as described above.

It should be noted that arrangements and embossed patterns are notlimited to employment of diamond shaped pockets or circular shapedpockets. Other shapes are contemplated. Some arrangements may evenutilize different pocket shapes within the same pattern.

The following table summarizes the characteristics of the differentpocket sizes, assuming the SAP concentration remains uniform throughoutthe core.

TABLE 1 Summary of Performance by Product Size and degree of SAPSaturation SAP Saturation Small Pocket Size Medium Large Dry Very highpermeability (0%) Moderate absorption rate High capacity remaining LowHigh permeability High permeability High permeability (10-20%) Highabsorption rate High absorption rate High absorption rate Low capacityModerate capacity High capacity remaining remaining remaining MediumHigh permeability High permeability High permeability (20-60%) Nofurther absorption Low absorption rate High absorption rate Low capacityremaining Moderate capacity remaining High — Moderate permeability Lowpermeability (60%+) No further absorption Low absorption rate Lowcapacity remaining

Systems, Method, and Structures for Absorbent Particles Constructionand/or Stabilization

In a further variation of providing an absorbent composite according tothe present disclosure, one or more of the nonwoven webs employed inprevious examples is replaced with a more open structure. Examples ofsuch a nonwoven include, carded PET webs, airthrough bonded nonwovens,resin bonded nonwovens and non-absorbent air-laid structures. Materialsknown as acquisition and distribution layers (ADL) are included in thislist of suitable materials. The resulting structure provides analternative means for containing absorbent particles and morespecifically, within a fibrous network but without using an absorbentmatrix of fibers (i.e., without pulp). The structure promotes thedistribution of the SAP within a network of fibers provided by thenon-woven web layer. This distribution of SAP particles into the moreopen web provides, among other things, a mechanism for furtherstabilization of the SAP within the nonwoven simply through entanglementof the particles within the fibrous network.

FIG. 16A illustrates a composite structure as previously described. Thecomposite employs a non-woven as a bottom layer (NW1) and a top layer(NW2) to sandwich a layer of SAP material (SAP). FIG. 16B illustrates analternative structure, wherein a bulky non-woven (“bulky” NW1) isemployed as a base layer. The bulky non-woven layer NW1 provides fibersthat extend outward and entangle SAP particles. Such entanglement withthe fibers in the more open material leads to stabilization of the SAPwithin the absorbent composite. In a manufacturing process, SAPparticles applied onto a sheet or web of the bulky woven may beenergized so as to promote penetration into the fibrous network of themore open nonwoven web. The effect of gravity on the particles may besufficient to promote the desired penetration as the SAP particles arelaid down onto the web. Techniques such as vacuum or vibration could beused to further enhance the penetration of the SAP particles into theopen, fibrous network.

Stabilization of the SAP prevents movement of the material duringprocessing, storage and use. In exemplary embodiments, the absorbentcomposite or core may employ the “bulky nonwoven” structure (as in FIG.16B) for stabilizing the SAP in addition to the use of adhesive andcontainers or pockets of SAP aggregates, as previously described.

It should also be noted that the more open nonwoven material can provideadditional performance features. These include faster acquisition offluid and improved dryness (rewet) for the user. Also, the absorbentmatrix will feel softer (spongier) than “flat” nonwoven webs, and willprovide a more flexible composite. This results in greater comfort forthe user and a better fit around the contours of the user's body leadingto less chance of leakage.

Referring now to the illustrations in FIGS. 17A-17B, the exemplaryabsorbent composite is preferably provided with top layer of “bulky”nonwoven. The illustrations may be regarded as simplifiedcross-sectional views of the composite in FIG. 15A. Because thesubstrate used to contain the SAP is an open structure nonwoven, it ischaracterized by large pores (˜2000 microns). Embossing will set andstabilize the local pore structure of the bulky, resilient fiber websubstrate. Areas wherein the embossing pattern is small (utilizes smallcontainers) (FIG. 17A) creates smaller pores (see FIG. 17A) compared toareas with larger embossing patterns (FIG. 17B) which creates largercapillary pores (17B). In other words, the smaller inter-fiber distancecharacterized by the smaller patterns lead to higher densities andhigher capillarity. The larger patterns provide greater inter-fiberdistances which lead to low density and low capillarity. The result ofthis combination of pockets across the core is an optimized wickingstructure, as illustrated in FIG. 17C. With larger pores situated in thetarget area and smaller pores away from the insult point, an effectiveconduit for fluid flow results. This conduit may be utilized totransport liquid against gravity more efficiently. (See illustration ofliquid movement in FIG. 17c ). Such an advantageous structure can becreated within the nonwoven substrate by the appropriate choice ofembossing patterns hence allowing the liquid to spread further,enhancing core utilization and intake.

In further embodiments and in reference to FIGS. 17C and 17D, 3-Dpatterns or contours may be formed during use (uptake of liquid) as aconsequence of SAP swelling. As shown in FIGS. 17C and 17D, differentsize pockets provide differences in swelling capacities, which in turnlead to differential swelling. In one respect, dams may be created bythe pockets with greater swells (i.e., larger pillows). This structuralconsequence helps to reduce side and waist leakage. In most cases,uncontrolled liquid (liquid pooling on the surface of the product) leadto product leakage. The 3-D topography generated as SAP swells isdefined by the embossing pattern size/frequency. An absorbent core thatcan self-generate a surface topography can inhibit cross-directionalsurface flow (to prevent side leakage) or discourage leakage at thewaist region (longitudinal ends of the core). The structure andarrangement of pockets in FIG. 15A would be well suited to achieve theseproperties in an absorbent core.

Further Exemplary Methods and Systems for Making an Absorbent CompositeEmploying SAP

In a method referred to as profiling, the SAP dosing rate is varied toproduce a profiled core. See e.g., U.S. patent application Ser. No.12/925,765 for profiled core designs, which document is incorporated byreference and made a part of the disclosure. The profiled core structureprovides improved diaper performance by providing more absorbentmaterial in areas of the core where it is needed. The profile may alsobe achieved by stacking multiple layers of the absorbent composite, butat different lengths (e.g., short top core, full length bottom core). Amore efficient solution may be to vary the SAP dosing rate duringapplication of the SAP and align the high SAP dose areas with the crotcharea of the diaper when the core is converted in the diaper line. Such amethod may be more efficient as it utilizes less nonwoven material thanthe stacked core. It is also cost effective.

In one embodiment, a powdered hotmelt adhesive is mixed with the SAP toprovide additional bonding. The SAP and adhesive mixture is distributedbetween the two nonwoven webs and the hotmelt adhesive is “activated” bypassing the composite through a heating device. Suitable devices includeheated rollers, infra-red heater and the like. The adhesive melts andbonds the SAP and nonwovens together. This can also be combined with thepatterned embossing/ultrasonic processes to produce pocket patterns asdescribed previously. Typically, the adhesive/SAP is mixed at a ratio of10 to 100 parts SAP to 1 part adhesive by weight (1-10% adhesive byweight). Too much adhesive will limit the absorption performance of theSAP, while too little adhesive may sacrifice structural integrity.Preferably, the adhesive is applied at a rate of about 1 to 2 particlesof adhesive per particle of SAP. The exact rates may be worked out ifthe average particle size and density of the SAP and adhesive are known.

The absorbent composites described thus far are well suited formanufacturing in both offline and online manufacturing processes. In theoffline process, the core machine stands separate to any other processand produces rolls, spools or boxes of festooned material that is thendelivered to the diaper converting line. Typically, but not necessarily,the machine associated with the product of FIGS. 6-7, as describedpreviously, would produce a wide sheet of the absorbent composite. Theproduct is then slit to produce a number of rolls of material for use onthe diaper converting line, e.g., a 1.5 m wide machine would produce 15rolls of material at 100 mm width. In the offline process, the offlinemachine will typically run at speeds much slower than the diaperconverting line. In the online process, the core machine is part of thediaper converting line and the core is made a part of the diaperconverting process. The output speed of the core machine must match thespeed of the diaper converting line and the width of the core will matchthe width of the core in the product.

In an offline process depicted in FIG. 18A, a SAP sandwich is formedhaving a substrate A, a second substrate B, and a SAP coating disposedbetween the two substrates. In one embodiment, the SAP is immobilized bybonding the two substrates together to contain the SAP in discreteplanar volumes between the layers. One or a combination of the followingmethods for SAP stabilization may be employed. In a first process, heatembossing or ultrasonic bonding is employed to fuse the substrate layersin a defined pattern. In a second process, an adhesive is applied to oneor both of the substrate inner surfaces. The two substrates are thenstrategically bonded together according to an advantageous embossingpattern. Thirdly, a thermal binder, such as low melting adhesiveparticles, may be mixed with the SAP particles. External heating is thenapplied to the composite to activate or melt the adhesive, therebybinding the particles to the substrate and to each other. Here, apatterned embossing step may be used to enhance the lamination qualitywhile maintaining a more open SAP layer structure for enhanced liquidintake. If a patterned is not desired, a smooth calendar roll (notpatterned) may also be employed to bond the cover layer to the SAP layerto produce the sandwich structure.

In an online process, the core forming process is directly coupled tothe diaper converting process. The SAP sandwich structure is formed aswith the first and second process discussed above, at speeds 3-4 timesthat of the offline process. The third method may not be suited to thefaster online process because of the short dwell time required to heatand activate the thermal binder that is mixed in with the SAP. Theoffline process is designed to produce a wide material at slower speeds.The material output is then slit into narrower widths to supply severaldiaper lines. In contrast, the online process is designed to produce anarrow (1-wide) material at higher speeds and supply core material foronly one diaper machine at a time.

So, in a preferred embodiment using the offline method according to thethird method described above, a small quantity (10% or less) of hot meltparticles is mixed in with the SAP. This particle mix is uniformlydeposited on substrate A and then, subjected to radiant IR heating tomelt the adhesive particles. The second substrate B is then laid on topwhile the material is still hot. The layers are immediately laminatedtogether using heat embossing with a patterned roll/smooth anvilembossing system. Table 2 below summarizes the process and providescertain parameters of a preferred embodiment.

TABLE 2 Exemplary Offline Process of Manufacturing Using Hot MeltAdhesive Core Substrate SAP BW, Substrate Bonding Structure A gsm HotMelt Activation B Pattern A 20-80 gsm 150-750 Abifor 1605, IR HeatingTissue Diamond, ADL web 5-10% 22 × 50 mm

A coating line manufactured by Santex, Tobel, in Switzerland may providethe SAP scattering technology, IR heating and web handling. See e.g.,FIG. 18B. As shown in FIG. 18B, a scatter unit utilizes a hopper and astandard rotating needle roll to mix and apply the mixture on the web.The SAP material is chosen according to its suitability for theapplication, but in general, SAP with high retention capacity and highabsorbency under load are preferred, for example, Centrifuge RetentionCapacity (CRC) of from 20-40 g/g, a Pressure Absorbency Index (PAI)greater than 100 g/g. An exemplary SAP is M-151 manufactured by NipponShokubai. A suitable hot melt adhesive is low melting EVA polymer,Abifor 1605, 0-200 micron particle size grade, which is currentlyavailable from Abifor Powder Technology, Switzerland. As shown in thedetail of FIG. 18, a readily available scatter unit employs a needleroll in mixing and applying the mixture on the web. The bonding patternspecified for this embodiment is an elongated diamond with a major axislength of 50 mm oriented in the MD direction and a minor axis length of22 mm. See e.g., FIG. 18C.

FIG. 19 depicts an absorbent composite 910 that is produced by themethod and system as described in respect to FIGS. 18A-18C above.Preferably, the composite 910 includes a bottom substrate A that is abulky nonwoven, a top layer or substrate B, and superabsorbent particlesS situated between the two layers and interspersed with hot meltadhesive particles HM (as described above). More preferably, the topsubstrate B is provided by a tissue material readily available andunderstood in the art. The top substrate B may, in the alternative, beprovided by a second bulky nonwoven layer or an SMS or spunbond(“non-bulky”) nonwoven layer.

As described above, a laminate of the absorbent composite 910 may bemanufactured on-line or off-line. The laminate may be modified toincorporate additional or differential SAP loading (i.e., Profiled Core)as also discussed above. In an off-line process, the composite may bedelivered as a wide sheet that is slitted and divided into individualcore composite sections.

FIGS. 20A and 20B are cross-sectional views of a disposable absorbentarticle 812 (laid flat) incorporating an absorbent core laminate 812 orabsorbent composite 810. For convenience in describing the accompanyingFigures, a complete absorbent composite extended to provide a completeabsorbent core of a disposable absorbent article may be referred to asan absorbent core laminate while an absorbent composite may be used todescribe components of a section or portion of the laminate. Elsewhere,including the claims, the terms may be used interchangeably. Theabsorbent core laminate 812 features a plurality of spaced apart pockets814 with an aggregate 816 of SAP (superabsorbent particles (S))contained therein. FIG. 20C provides a detail cross-sectional, elevatedview of one of these pockets 814. FIG. 20C also depicts the componentsof a preferred absorbent composite 810.

Now referring to FIG. 28, a basic disposable absorbent article 862 (in alaid flat state) is shown incorporating an absorbent core laminate 812as the absorbent core, according to the disclosure. The absorbent corelaminate 860 is completely covered by a topsheet 864 but, forconvenience, the topsheet 864 is shown to be transparent. The absorbentcore laminate 860 is supported on a wide backsheet 866 with side margins868. Each side margins 868 is provided with a cutout that exhibit aconcave shape on either side of the absorbent core laminate 860. Asgenerally known, the concave cutout will coincide or correspond to legholes about the thighs of the user.

Referring again to FIG. 20C, in a preferred construction, a nonwovenmaterial provides a base or bottom layer 818 of the composite (duringmanufacture of the absorbent article product). During product use, thebase layer 818 may be described as being positioned away from the body,as opposed to being positioned on the body-side of the absorbentcomposite 810 in direct receipt of intake. Further in this embodiment,the base nonwoven layer 818 has an adhesive layer 822 applied thereon.The adhesive layer 822 is preferably delivered, as a continuous bead,atop the base nonwoven 818 and in an advantageous open pattern, as willbe described below.

The absorbent composite also includes a SAP layer 806 positioned abovethe adhesive layer 822 and in between the bottom nonwoven 818 and a topnonwoven layer 826. In this embodiment, the SAP layer 824 is composed ofSAP particles S only, without any form of binder material or matrix. Itmay be described also as being fluffless or pulpless. The top nonwovenlayer 826 is preferably provided by a bulky nonwoven material withfibers that extend toward and laterally entangle some SAP on or near thetop surface of the SAP layer 806. The top nonwoven 826 is preferablybonded to the base nonwoven 818 by embossing and more preferably, bypoint bonding. Bond points 828 define the periphery of the pocket 814and also, compress the resilient bulky nonwoven 826 at the pocketperiphery to present an overall bubble or domed cross section (as shownin FIG. 20C). The simplified illustration of FIG. 29 provides analternate view of the absorbent composite 810 and, more particularly,the components of the composite, without showing point bonding andcompression about the periphery of the pocket 814.

In this preferred construction, the bulky non-woven layer 826 contactsand covers the SAP layer 824 thereby restricting travel of SAP particlesS. The bulky non-woven layer 826 is also advantageously positioned as atop layer during manufacturing and product handling, thereby restrictingtravel or migration of SAP particles even before use. During use of theabsorbent article, the bulky non-woven 826 is also advantageouslypositioned on the bodyside to receive and distribute intake to the SAPlayer and beyond.

In this preferred construction, the SAP is organized into discrete,spaced-apart aggregates or clumps 816 of SAP, each of which ismaintained in a pocket or container 814 as described previously. The twonon-woven layers 818, 826 are bonded at bond sites or, morespecifically, at an arrangement of discrete, spaced-apart bond points828. The bulky non-woven 826 is, therefore, multiply and intermittentlysecured over the SAP aggregates 816, and helps maintain the SAPaggregates 816 in place. The unique functions and properties imparted onthe absorbent composite and absorbent core laminate through use of thebulky nonwoven are described further below.

The exploded view of FIG. 21 reveals the various components or layers ofthe absorbent composite 810 or absorbent laminate 812 and their relativepositions, according to a preferred embodiment. FIG. 22 providesadditional exploded views that illustrate a basic process or steps formaking the composite, by showing the order by which the components ofthe composite are brought together. Reference should also be made topreceding descriptions of making an absorbent composite or an absorbentarticle employing the composite, including FIGS. 1-5 and descriptionsassociated therewith. Many of the process steps and process componentsdescribed therein may be applicable or adaptable for use in the makingof the absorbent composite of FIGS. 19-29.

In an initial step of the preferred method, a web of nonwoven 818 isconveyed in the conventional manner and then, passed beside an adhesiveapplicator. The spray adhesive applicator preferably delivers acontinuous bead onto the nonwoven 818 in an open adhesive pattern (seeFIG. 22A). In this way, loops of adhesive 822 a are provided on thesurface of the nonwoven material 818 characterized by or defining openregions free of adhesive (rather than a uniform layer or film). Theloops 822 a in exemplary embodiments are smaller (i.e., width ordiameter) than the pockets 814 previously described, with diameterstypically in the order of 1 mm to 25 mm.

FIG. 22B illustrates the delivery of SAP aggregates 816 by methodsdescribed herein, or otherwise known in the art, onto a substratecomposed of the base nonwoven layer 818 with an adhesive layer 822 oropen pattern pre-applied thereon. Specifically, SAP is delivered via anairstream and, through the use of a conventional vacuum system orsuction mechanism, such as those previously described herein orotherwise known in the art. Suction applied on and beneath the web ofnonwoven 818 draws SAP toward the nonwoven 818 and organizes the SAPinto the desired prearrangement of aggregates or clumps 816 of SAP (asshown in FIG. 22B). The vacuum system may employ a screen or meshinterface to better engage the bottom of the non-woven and define thetarget geometry of the SAP aggregates. Thus, the interface presents asuction pattern that corresponds with the desired pocket pattern of theSAP aggregates 816. The vacuum system preferably draws the SAP directlyfrom the stream above the web and into discrete clumps or aggregates onthe web above the suction mechanism. Certain regions, including regionsalong the sides and ends are designated as SAP-free (as well asadhesive-free) zones and will be purposely left free of SAP.

SAP generally falls directly into the desired arrangement as opposed tobeing first distributed across the web and then moved about the webbefore forming tighter concentrations on the web (as in alternateembodiments). The SAP generally does not have to travel over adhesive onthe web to form the target plurality of SAP aggregates 816. Theresulting web is, therefore, composed of a nonwoven base layer 818 withan open adhesive pattern 822 thereon and an arrangement or layer 806 ofdiscrete, spaced apart SAP aggregates 816. The clumps of SAP generallylay on and contact the adhesive, but the open pattern of the adhesiveoccupies substantially less than the bottom layer of that SAP aggregatecontacts. It should be noted, however, that a SAP particle contactingadhesive may be generally immobilized. Another SAP particle positionedadjacent and in contact with such immobilized SAP particle may, in turn,be restricted (in movement) by and at least partly immobilized by thatSAP particle (and/or other adjacent SAP particles). Such frictionmechanism at least hinders horizontal movement of SAP particles.

As the web of nonwoven-SAP moves forward and away from the vacuumsystem, the adhesive pattern 822 acts to maintain the desiredarrangement and position of SAP aggregates 816. In a subsequent step, aweb of a second nonwoven 826 is conveyed toward and then applied overthe nonwoven-SAP laminate. See FIG. 22C. As discussed above, thepreferred top nonwoven 826 layer is a bulky nonwoven. With furtherprocessing and travel of the SAP aggregates 816 in a process of makingan absorbent article such as a diaper or training pants, the additionalnonwoven 826 provides additional cover and acts to retain the SAPaggregates 816 in the desired pattern. In addition to providingadvantageous functions in the finished product and during use, the bulkynonwoven 826 entangles top layered SAP particles S, as represented inFIG. 29, thereby furthering the immobilization of the SAP aggregates 816(during product manufacture and then post-manufacture product handling).Entanglement of the SAP with the fibers of the bulky nonwoven restrictslateral and vertical movement of SAP near the top of the SAP aggregate816 and also hinders movement of SAP directly beneath it. As notedherein, the SAP and bulky nonwoven are defined and selected inconsideration of the desired degree of entanglement and penetration.

Next, the web of two nonwovens and SAP aggregates therebetween is passedover to a calendar roll that engages and compresses the web. Thecalendar roll is equipped with a surface engraving having a pattern thatcorresponds with the pocket pattern on the web, as described previously.FIG. 23 depicts a typical bonded absorbent composite laminate 812 usingdiscontinuous point bonding. The dots reflect indentation in the bulkynonwoven 826 after embossing. The dots are also the bond points 828 forthe pockets 814 (see also the cross-sectional views of FIGS. 20A-20C).Securing the two nonwovens together about the SAP aggregates 816provides another mechanism for maintaining the arrangement of SAPaggregates 816 and the resultant absorbent laminate 812. As will bediscussed herein, the arrangement of bond sites provides a geometricgrid 830 that locate and define the pockets 814 of SAP aggregates 816.

Thus, in this exemplary embodiment, the preferred SAP laminateconstruction draws from several structural features to inhibit themigration of SAP particles from the desired arrangement of SAPaggregates during absorbent article product manufacture andpost-manufacture handling. First, adhesive is provided on the basenon-woven layer and SAP aggregates are laid on the adhesive. Theoptional adhesive layer is delivered, however, in an open pattern ofclosed loops that contact only certain bottom layered SAP particles butinhibit travel of SAP particles beyond these contacted SAP articles. Theapplication of the top nonwoven layer over the SAP aggregates augmentsthe minimally-applied adhesive to further restrict movement of the SAP.Advantageously, the SAP layer delivered onto the base nonwoven ispulp-free and free of a matrix or binder, which optimizes thecomposite's absorption and fluid handling properties. It is also free ofadhesive but for the bottom layer of adhesive. Thus, much of the SAPlayer, particularly, the middle part of the SAP layer, consists of SAP,although other materials may, in alternative embodiments, be included toimpart beneficial properties. The predominance of the SAP-onlyconstituency results in a thinner, softer, more flexible SAPconstruction, as discussed previously. Also, the large sections ofSAP-only constitution, which are adequately maintained in position(inhibiting SAP particle migration), provide improved absorbentproperties and fluid handling characteristics.

As a further enhancement, the preferred SAP laminate constructionutilizes an arrangement of discrete or intermittent bonding points inconjunction with the laminate construction of FIG. 22. See FIG. 23. Theembossing pattern that provides the intermittent or spaced part bondingpoints provides a synergistic effect with utilization of the SAPlaminate construction of FIGS. 20-22 and/or the use of a bulky nonwovenlayer as a top or bodyside layer of the absorbent laminate (or viceversa). The gap provided between bond points allow for fluid to passbetween SAP aggregates, including fluid flow passing from the SAP-onlymiddle sections of the SAP laminate. The provision of the bulky nonwovenand/or adhesive reduces the need for complete or continuous bondinglines. Similarly, the position of the bulky nonwoven and/or pointbonding reduces the amount of adhesive required for SAP stabilization.

Furthermore, reduced constriction of the bulky nonwoven layer by usingthe embossing points, rather than longer bond points or solid bondlines, allow for the resilient bulky woven to expand and advantageouslyreceive and distribute fluid intake. Pressure applied by the embossingcompresses the bulky nonwoven at the bond point as shown in FIG. 20C,but the resilient bulky nonwoven “bounces up” from the bond point. Seealso FIG. 30. This results in a more open substructure well capable offluid handling functions. Further, the SAP-only constituent functions toreceive and absorb the fluid intake and, as necessary, pass fluid intaketo adjacent SAP pockets via the gap between bonds. In one respect, thereis a fluid channel that runs from the top surface of the relatively openbulky nonwoven layer, through the bulky nonwoven layer, and into theSAP-only body, and from the SAP-only body middle layer, sideways throughthe gap between bond points, and then into another preferably,substantially SAP-only aggregate.

The plan view of FIG. 24 presents a bonded absorbent core laminate 812mutually secured by discrete bond points 828. FIG. 24 depicts apreferred pattern of SAP pockets 814, according to this exemplaryembodiment. The laminate 812 is elongated having a lateral widthdimension and a longitudinal length dimension. The shape of the laminate812 at this stage is generally rectangular. The embossing processpreferably employs an intermittent bonding pattern to enhance fluid flowbetween pockets, as described above. The selected pocket pattern usesdiamond shaped embossing to produce diamond shaped pockets 814. Anadvantage to the use of a diamond shape pockets and the correspondinggrid is that, with its straight, intersecting lines, it is easier todesign and match engraving patterns on embossing rolls and interfacesfor vacuum systems.

Preferably, the diamond shapes are arranged such that the embossinglines or series of bond points are not square with the side margins ofthe core. The straight lines (SL) that aligned bond sites may present onthe surface of the laminate 812 are advantageously oriented at less thana ninety degree angle to the side margins and more preferably, betweenabout 60 degrees and 30 degrees. In this way, the interconnected bondinglines (SL), which can provide a potential fluid pathway (i.e., above thesurface as well as in the pockets 814 and along the lines) are longerthan a perpendicular line to the side margins 834 (which another patternmay represent). This addresses possible fluid leakage to the side margin834 and encourages fluid path diversion into non-saturated pocketsdownstream.

The absorbent core laminate 812 also features SAP free lanes 838proximate side margins 834 and proximate end margins 836. The steps fordelivering SAP and organizing SAP aggregates on the bottom nonwovenlayer are designed to leave these regions free of SAP to minimized SAPusage. The regions are later sealed and in the case of the side margins,a curved section may be cut out of the absorbent core laminate 812 toaccommodate leg cutouts and/or produce an hourglass shaped core. Theabsence of SAP in these regions makes for a more flexible and foldablematerial layers. This also avoids having to cut (or seal) through therelatively harder, stiffer SAP material as may be required in themanufacturing process, thereby promoting cleaner and more precise cuts(and seals). Perhaps, more importantly, this avoids extra wear oncutting blades and maintenance and downtime of manufacturing equipment.

The plan view of FIG. 25 illustrates an alternative absorbent corelaminate 840 employing an alternative pocket pattern and bondingpattern. Instead of intermittent bonding, the bond pattern employscontinuous bond lines 842 that generates a solid grid. As with thepreviously described embodiment, diamond shaped pockets 844 are used.Among other things, the potential fluid pathway created by theconnection of the bond lines is directed to an angle away from the sidemargin (i.e., 45 degrees), thereby somewhat mitigating the risk ofdirect fluid strand to side margin.

As used herein, diamond shaped pockets mean a pocket having four sidesand with two corners preferably mutually aligned with the longitudinaldirection and the other two corners with the lateral directions. Thepockets are preferably not oriented as rectangles square with thelateral and longitudinal centerlines of the laminate, wherein bond linesmake for a “direct” straight line path to the side margins. As usedherein, the term “grid” means the geometry established by intersectinglines along the bond sites or embossing line. Further, as used herein inrespect to an arrangement or geometry of pockets, “direct” straight linepath means one or more bond lines that connect to make for a continuousand unobstructed (not “broken”) path from proximate the longitudinalcenterline to the side margins wherein, the path is generallyperpendicular to the side margins. Such a direct straight-line pathmakes for the shortest fluid path to the side margins. For clarity, suchstraight line paths that are more than thirty degrees deviated from theperpendicular shall be referred to as an indirect straight line path anddo not direct straight line paths. Straight line paths that are not sodeviated are considered “direct straight” line paths.

It should be noted that other “grids” and other pockets shapes andpocket arrangements may be employed. Some pocket shapes employed willnot exhibit any direct or for that matter, any straight line, paths tothe side margins. These include some arrangements previously describedherein, including arrangement of circle or elliptical shaped pockets.

Profiled Core Composite

In this preferred embodiment, the method of manufacturing an absorbentcore includes steps for delivering a profiled core construction. Themethod is a further version of the method previously described, and inone preferred process, incorporates all of the steps of the previousmethod. For example, while the earlier method may employ a single SAPapplicator, the present method employs a second SAP applicator toaugment SAP delivery by the first SAP applicator. The second SAPapplicator may be positioned upstream (in front) or downstream of thefirst applicator. Whereas a nozzle of the first applicator may be sizedto cover the width of the target core, the second applicator may besized to cover a narrowed portion of the core. Further, the secondapplicator may be programmed for delivery for a specified period that isa fraction of the delivery period of the first applicator. For example,the first applicator may be programmed to continuously deliver to almostthe entire width of the SAP core (except for a narrow SAP-free lane atthe side margins). The second applicator may be sized and programmed todeliver SAP to a narrower central region and/or for an intermittentperiod that will correspond to a central region of the core. Inexemplary embodiments, the second SAP applicator is positioneddownstream of the first SAP applicator thereby delivering a second doseor load of SAP over the SAP first deposited on the web of nonwoven.Thus, the arrangements of SAP aggregates sourced by the secondapplicator (as well as the first applicator) have a higher SAP loadingthan other SAP aggregates sourced only by the first applicator.

As before, the preferred process employs suction mechanisms and screensto organize the SAP pockets on the web. Upon delivery, the SAP loads arequickly drawn into the SAP aggregate formation. SAP aggregates sourcedby two SAP applicators provide pockets with a thicker and larger SAPlayer, than pockets that are not so sourced.

In the preferred arrangement, the dual SAP-loaded pockets are located ina central region where most intake occurs. In further embodiments, theconstituents of the two SAP loadings may be varied to achieve a desiredmixture or the desired absorbent or fluid handling properties. In yetfurther embodiments, additional SAP applicators may be employed andstrategically located to produce the desired SAP pocket pattern andfunction.

Use of Bulky Nonwovens

The “bulky” nonwoven referred to herein is, and provides, an open,fibrous network or web of hydrophilic but non-absorbent fibres. Further,as used herein, a bulky nonwoven is a fibrous web material having athickness of between 100 μm and 10,000 μm (preferably 1,000 μm to 5,000μm), basis weight between 15 g/m² and 200 g/m² (preferably, between 20g/m² and 80 g/m²), and density between 0.01 g/cc and 0.3 g/cc(preferably between 0.01- 0.08 g/cc). Moreover, the bulky nonwoven willhave an effective pore diameter between 300 μm to 2000 μm. Typically,particles of the SAP selected will have an average particle size ofabout 300 μm, which ensures some penetration or entanglement between SAPand the selected bulky nonwoven. The tables shown in FIGS. 31 and 32 maybe used in further defining the bulky nonwoven and showing theinterrelation between the key properties. (The shaded areas in theTables of FIGS. 31 and 32 point to bulky nonwoven materials according tothe disclosure.) The effective pore diameter is estimated from webdensity, fiber diameter and fiber density values following the method ofDunstan & White, J. Colloid Interface Sci, 111 (1986), 60 whereineffective pore diameter=4*(1-solid volume fraction)/(solid volumefraction*solid density*solid specific surface area).

Suitable fibres include polypropylene (PP), polyethylene (PE),polyethylene terephthalate (PET), polylactic acid (PLA), polyolefins,copolymers thereof and any combination thereof including bicomponentfibres. The fibres are usually treated with a surface active agent,surfactant, to modify the surface tension of the fibres so that they arehydrophilic.

As described above in respect to FIGS. 16 and 17, there are fluidhandling benefits that arise from the employment of a bulky nonwoven asa fabric in the absorbent composite. Furthermore, orientation of theabsorbent composite with the bulky nonwoven positioned on the body sideis particularly advantageous as it enhances the absorbent composite'scapacity for acquisition and distribution of fluid intake. The bulkynonwoven has a high void volume and permeability, and allows thecomposite to quickly capture and efficiently distribute the fluid awayfrom the insult point.

Additionally, the bulky nonwoven with the embossing patterns describedalso has the following features:

The “pillow” structure (see e.g., FIG. 20C, FIG. 29 and FIG. 30)provided by the bulky nonwoven as a bodyside layer creates acompressible and resilient structure that enhances the perception ofsoftness.

Within a pocket area, a pore size gradient exists (see e.g., FIG. 20Cand FIG. 30) that encourages the liquid to move from the crests (moreopen area with larger interfiber distance, I) to the bonded area (moredense area with smaller interfiber spacing). This is illustrated in FIG.30 which shows the bulky nonwoven 826 exhibiting smaller interfiberdistances I toward the bond point 828. Since capillarity is inverselyrelated to density, the capillarity of the denser area is higher thanthe more open area hence liquid within the nonwoven will tend to bedrawn towards the denser areas. This is particularly important fordryness perception since it allows any remaining liquid at the crests todrain away towards the bonded areas and further into the underlying SAPstructure where the liquid is tightly held. Hence, a top surface that isrelatively free of liquid is created which contributes to the perceptionof dryness. This pore gradient also discourages fluid from flowing backto the surface.

The discontinuous bonding pattern also contributes to the softnessperception by creating a more flexible composite.

Spray Adhesive

Adhesives can be used to provide additional bonding for the compositeand can be used to help secure the SAP on the nonwoven. This is neededduring manufacture of the composite, subsequent and further processingof the disposable absorbent article incorporating the composite, and thestorage and eventual use of the composite in the absorbent article.Ideally, the adhesive is applied to at least one of the nonwoven webs ofthe composite or adhesive can be applied to both the upper and lowernonwoven webs.

Suitable adhesives include hotmelt adhesives that are applied by eithera slot coat or a spray coat applicator (such as those supplied byNordson Corporation). In a preferred embodiment, the adhesive is appliedby a spray method where continuous beads of hotmelt adhesive aredirected by air streams into patterns, such as a spiral pattern or amore random pattern. FIG. 22 show one such pattern. The diameter of thespiral is in the range of 1 mm to 25 mm. The advantage of such spraypatterns is that the adhesive coverage on the nonwoven web is notuniform and there are open areas that are substantially free ofadhesive. These open areas provide unrestricted access for fluid flowthrough the nonwoven web and into the superabsorbent layer, whereas auniform coating may slow down or reduce the flow of fluid through theweb.

To illustrate possible variations of the preferred embodiment, FIG. 26provides an exploded view of an absorbent core laminate 850 according toan alternate embodiment. The absorbent core laminate 850 employs a basenonwoven layer 818 with an adhesive pattern 822 pre-applied thereon, asdescribed previously. The laminate 850 also provides a first layer 816of spaced apart SAP aggregates that occupy substantially all of thelateral and longitudinal expanse of the laminate 850. The adhesivepattern 822 and the SAP aggregates may be applied as describedpreviously, with the SAP being delivered by a SAP applicator andorganized into the desired pocket pattern with the aid of a conventionalvacuum system and the like, as described previously. In this variation,a second SAP applicator may be positioned downstream of the first SAPapplicator to deposit SAP onto a selected region(s) of the web havingthe first layer 816 of SAP aggregates already provided thereon. A regionselected to receive additional SAP constituent or perhaps, absorbentmaterial having properties different from the SAP first delivered, istypically a central region that will correspond to a crotch region whenthe disposable absorbent article is in use. In the process in which themachine direction of the laminate 850 coincides with the lateraldirection, the SAP applicator may be equipped with a nozzle or sprayarea that is narrower than that of the first SAP applicator. The regionon which SAP is delivered will, therefore, be narrower than the SAPlayer 816. If the machine direction coincides with the longitudinaldirection, the second SAP applicator may be programmed to deliver SAPonly during a period aligned with travel of the central region under thesecond SAP applicator.

Referring to FIGS. 20A and 20B, the pockets 814 in a central region 854contain concentrations or SAP aggregates that are greater than SAPconcentrations in pockets 814 near longitudinal end regions 856 of theabsorbent core laminate 812. Intermediate of these regions and thecentral regions, there are pockets 857 containing SAP in concentrationsthat is somewhere in the middle. The concentrations of SAP in thesepockets 857 may be determined by the extent of the second SAP applicatorand possibly a sharing of excess SAP between adjacent pockets. Thesepockets 857 may serve as a gradual transition between high and lowcapacities of SAP and absorption and swell properties, and may producebeneficial fluid flow (across the absorbent core), as discussed herein.

Referring again to FIG. 26, this embodiment is also equipped with asecond adhesive pattern 862 to help secure SAP in the pockets. Theadhesive pattern 862 may be identical to the open pattern 822 preferredfor application on the bottom nonwoven, and will be pre-applied to thetop nonwoven 826 before introduction of the top nonwoven 826 into theresulting laminate 850. In the resulting construction, this secondadhesive pattern 862 helps secure particles of the SAP aggregate thatcontact or nearly contact the top non-woven 826. If a bulky nonwoven isemployed as a top nonwoven 826, the adhesive helps secure SAP in the toplayer region of the SAP aggregate with fibers of the bulky nonwoven,including promoting SAP entanglement. It is possible that when twoadhesive patterns are employed in a laminate design, as with thelaminate of FIG. 26, the total amount of adhesive (e.g., thickness ofthe bead, size of the loops) used in each pattern may be reduced.Moreover, the number or frequency of bond points may also be reduced.The various mechanisms for securing SAP in the pockets 814 actdifferently on the SAP and from various perspectives, but work togetherto obtain a common objective.

FIG. 27 illustrates a subsequent stage in an exemplary process of makingan absorbent core laminate and/or disposable absorbent article. A web870 of separable absorbent core laminates 872 is shown being conveyedwith the lateral direction coinciding with the machine direction. Thelaminates 872 are shown being prepared with an hourglass shape. Thedelivery of SAP onto the bottom nonwoven is provided such that SAP-freeregions 874 are present near or along the eventual side margins 876 ofindividual absorbent core laminates. Furthermore, as shown in FIG. 27,wider regions 878 near the center of the side margins 876 are also voidof SAP in preparation of a cut to accommodate a leg hole and/or simply,produce the preferably hourglass shape that helps to more readily fit oraccommodate the user around the crotch region. In this way, SAP usageand material cost may be reduced.

In any event, a narrow region or layer 852 of SAP aggregates isdeposited atop the first layer 816, and in the selected central region.The vacuum system may again be employed to direct the deposit of SAP tothe target areas. In this way, SAP aggregates of higher concentrationsare generated.

Typically, the absorbent core laminate 812 is elongated with a pair oflongitudinally-spaced apart end regions 856 and a central region 854therebetween. The absorbent core laminate is situated between thetopsheet and backsheet in what is referred to as a “core envelope” 880.See also cross-sections FIGS. 20A and 20B. FIG. 20A may be described asa cross-sectional view laterally across the core envelope 880 (i.e., across lateral centerline XX) while FIG. 20B is a cross-sectional viewlongitudinally across the core envelope 880 (i.e., across longitudinalcenterline YY). Absorbent core laminate 812 may also be described ashaving side margins that extend between the end regions 856. Anarrangement of the pockets 814 of SAP aggregates 816 is set between theside margins 812. As can be seen from the drawings, the arrangementdefines a pattern or grid on the absorbent core laminate 812. About thecentral region 854, a pair of cutouts 882 into the side margin 856provides a concavity in the generally rectangular laminate 812, whichreduces the population of pockets 814 in the central region 854. Theconcavity makes for a generally hourglass shape to the absorbent corelaminate 812. As the central region 854 generally corresponds withcrotch region of the disposable absorbent article 862, the concavity ofthe absorbent laminate 812 and general absence of the relatively stiffer(than the topsheet and backsheet material) core material facilitates thedeformation of the absorbent article 862 in the crotch region during useand helps to accommodate the contour of the user.

The present disclosure is, therefore, well adapted to carry out theobjects and attain the ends and the advantages mentioned, as well asothers inherent therein. While presently preferred embodiments (in theform of a diaper) have been described, numerous changes to the detailsof construction, arrangement of the article's parts or components, andthe steps to the processes may be made. For example, the varioustopsheets, backsheet, absorbent core, containment walls and otherabsorbent composite structures may be utilized in other parts of thearticle or with other articles other than diapers. Such changes willreadily suggest themselves of those skilled in the art and areencompassed within the spirit of invention and in the scope of theappended claims.

Although the present disclosure and its advantages have been describedin detail, it should be understood that various changes, substitutionsand alterations can be made herein without departing from the inventionas defined by the appended claims. Moreover, the scope of the presentapplication is not intended to be limited to the particular embodimentsof the process, machine, manufacture, composition of matter, means,methods and steps described in the specification. As one will readilyappreciate from the disclosure, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized. Accordingly, the appended claims areintended to include within their scope such processes, machines,manufacture, compositions of matter, means, methods, or steps.

1. An absorbent core composite for a disposable absorbent article,comprising: a first fabric; a body side second fabric; and a pluralityof aggregates of superabsorbent particles (SAP) situated between saidfirst and second fabric; wherein, about each of a plurality of said SAPaggregates, an arrangement of spaced apart bond sites secure the secondfabric to the first fabric and form a pocket in which the SAP aggregateis secured between the first fabric and the second fabric; whereinspaced apart bond sites about said SAP aggregates provide gaps betweenbond sites that communicate one of said pockets with an adjacent saidpocket; and wherein said body side second fabric is a bulky nonwovenincluding fibers entangling at least some particles in said SAPaggregate.
 2. The absorbent core composite of claim 1, wherein each saidSAP aggregate is free of an absorbent matrix.
 3. The absorbent corecomposite of claim 1, wherein said SAP aggregates consist ofsuperabsorbent particles.
 4. The absorbent core composite of claim 1,wherein said second fabric includes fibers that penetrate the SAPaggregate at a top layer of superabsorbent particles, the SAP aggregatebeing free of an absorbent matrix.
 5. The absorbent core composite ofclaim 1, further comprising: an adhesive pattern applied on the firstfabric and adhesively contacting superabsorbent particles of said SAPaggregate positioned in a bottom layer of particles in said SAPaggregate adjacent said first fabric, to at least partially secure thesuperabsorbent particles of said SAP aggregate.
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 7. Theabsorbent core composite of claim 1, wherein said open regions free ofadhesive generally have a width or diameter less than a width ordiameter of said pockets situated on said adhesive pattern.
 8. Theabsorbent core composite of claim 1, wherein said bulky nonwoven secondfabric has a thickness between 1,000 μm to 5,000 μm, density between0.02 g/cc and 0.07 g/cc, basis weight between 20 g/m² and 80 g/m²,density between 0.01 g/cc and 0.08 g/cc, and effective pore diametergreater than 300 μm.
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 16. Theabsorbent composite of claim 1, wherein said bond sites are intermittentbond points.
 17. The absorbent composite of claim 1, wherein each saidfabric is pre-applied with an adhesive pattern having loops definingopen regions free of adhesive; and wherein said SAP aggregates arepulpless and free of an absorbent matrix.
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 66. The absorbent core composite of claim 1, wherein eachsaid SAP aggregate is free of an absorbent matrix.
 67. The absorbentcore composite of claim 1, wherein said SAP aggregates consist ofsuperabsorbent particles.
 68. The absorbent core composite of claim 1,wherein said second fabric includes fibers that penetrate the SAPaggregate at a top layer of superabsorbent particles, the SAP aggregatebeing free of an absorbent matrix.
 69. A method of manufacturing anabsorbent composite laminate for a disposable absorbent article,comprising: conveying a first fabric into position to receivesuperabsorbent particles (SAP); depositing SAP on said first fabric toprovide discrete aggregates of SAP; conveying a second fabric; bondingsaid first and second fabric by embossing at a network of spaced apartbond sites to form an elongated laminate having a plurality of pocketsof SAP aggregate, whereby each pocket is defined by spaced apartembossing lines and gaps therebetween encircling about SAP aggregate andsecuring the second fabric to the first fabric; and conveying theelongated laminate, whereby said said pockets inhibit SAP particlemigration from said pockets.